Construction material

ABSTRACT

A structural material of a polystyrene base and the reaction product of the polystyrene base and a solid phosphate ceramic is applied as a slurry which includes one or more of a metal oxide or a metal hydroxide with a source of phosphate to produce a phosphate ceramic and a poly (acrylic acid or acrylate) or combinations or salts thereof and polystyrene or MgO applied to the polystyrene base and allowed to cure so that the dried aqueous slurry chemically bonds to the polystyrene base. A method is also disclosed of applying the slurry to the polystyrene base.

CONTRACTUAL ORIGIN OF THE INVENTION

The United States Government has rights in this invention pursuant toContract No. W-31-109-ENG-38 between the U.S. Department of Energy andThe University of Chicago representing Argonne National Laboratory.

TECHNICAL FIELD

This invention relates to forming polymer modified chemically bondedphosphate ceramics. In particular, this invention addresses a need toform a room-temperature-setting ceramic based on the conventionalCeramicrete® and Ferroceramicrete technology that will bond polymericsurfaces such as Styrofoam.

BACKGROUND OF THE INVENTION

Haematite, having the chemical formula Fe₂O₃, is one of the mostabundant minerals in nature. It exists as iron ore, in other mineralssuch as bauxite, and is also a component in clay minerals. It is themajor component in laeritic soils (red soils found in the tropics).Similarly, manganese oxide, having a formula Mn₂O₃ is also a very commoncomponent in several laeritic soils and also exists as a mineral ofmanganese in the tropics.

U.S. Pat. Nos. 5,645,518 and 5,830,815 issued to Wagh et al. on Jul. 8,1997 and Nov. 3, 1998, respectively, disclose processes for utilizingphosphate ceramics to encapsulate waste. U.S. Pat. No. 5,846,894 issuedto Singh et al. on Dec. 8, 1998 discloses a method to produce phosphatebonded structural products from high volume benign wastes. None of thesepatents provides a method for utilizing the waste materials of iron andmanganese.

U.S. Pat. No. 6,153,809 issued to Singh et al. Nov. 28, 2000 and U.S.patent application Ser. No. 09/751,655 filed Dec. 29, 2000, publicationno. U.S. 2002/0123422 to Wagh et al. represent additional development ofthe use of chemically bonded phosphate ceramics to useful materials.Each of the aforementioned patents, that is U.S. Pat. No. 5,645,518issued to Wagh et al., U.S. Pat. No. 5,846,894 issued to Singh et al.,U.S. Pat. No. 5,830,815 issued to Wagh et al., U.S. Pat. No. 6,153,809issued to Singh et al., U.S. Pat. No. 6,133,498 issued to Singh et al.and the above-identified publication no. US 2002/0123422 (U.S. patentapplication Ser. No. 09/751,655) is incorporated herein in theirentireties.

The phosphate ceramics disclosed in the various patents and publicationhereinbefore mentioned illustrate a continuing effort to use thechemically bonded phosphate ceramics disclosed therein for a variety ofpurposes including the encapsulation of hazardous or radioactive wasteas seen in the aforementioned publication, as well as the production oflow cost structural materials. Accordingly, therefore, a need exists inthe art for a low cost structural material which combines with syntheticorganic resin based structures, for particular usage in the constructionindustry. Typically, in warm weather climates, low cost housing may beconstructed using styrofoam as a base material onto which is sprayed aconcrete-like material as a finish coating to seal the styrofoam basematerial against the elements and to provide a satisfactory lookingstructure. Heretofore, the phosphate ceramics disclosed in theabove-captioned patents and publication were used as a finish coating inwarm temperature climates but have not been satisfactory because thebond between styrofoam and the phosphate ceramics herein above disclosedis physical and peelable such that durable coatings have not been ableto be provided with the extant material.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a structural materialand method for chemically bonding the phosphate ceramics hereinbeforedisclosed to foam material and particularly to polystyrene foam.

Another object of the present invention is to provide a method to coatstyrofoam structures with a material which cures or sets at roomtemperature and is easy to apply in the field.

Yet another object of the present invention is to provide an aqueousbased material which may be applied to a styrofoam or other syntheticorganic resin in the field at low cost and with high efficiency.

Another object of the invention is to provide a method for preparing andchemically bonding a phosphate ceramic to a polymer foam.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention consists of certain novel features and a combination ofparts hereinafter fully described, illustrated in the accompanyingdrawings, and particularly pointed out in the appended claims, it beingunderstood that various changes in the details may be made withoutdeparting from the spirit, or sacrificing any of the advantages of thepresent invention.

FIG. 1 is a schematic representation of the dissolution of poly (acrylicacid) sodium salt;

FIG. 2 is a schematic representation of the bonding of the dissolvedpoly (acrylic acid) with ceramicrete; and

FIG. 3 is a schematic representation of the stabilization of acrylicacid with magnesium and styrene.

Although the invention has been described particularly with respect topolyacrylic acid sodium salt, as hereinbefore stated, other acrylatesand the salts thereof are also applicable to the present invention andthe invention is not limited to the disclosed materials of polyacrylicacid salt, polymethylmethacrylate, polyacryl amide and polyacrylnitryl.However, while the above description is particularly suited to providinga material which chemically bonds with polystyrene foam by theincorporation of styrene into the aqueous slurry, other systems may beused with the present invention wherein the ceramicrete orferroceramicrete is combined with water soluble powders and astabilizing or cross-linking polymer in an aqueous solution in order tochemically bond the resultant material to the synthetic organic resinstructure.

DETAILED DESCRIPTION OF THE INVENTION

The process and product disclosed herein provides an inexpensiveconstruction material, particularly adapted for use in warm weatherclimates where styrofoam or other synthetic organic resin foams are usedas construction materials and require a coating of a hard, densematerial for a surface finish. There are a large variety of materialswhich may be used to form the slurry which is thereafter chemicallyadhered to the synthetic organic resin foam base or surface. One suchmaterial is haematite which may be used in combination with sand, flyash, and a variety of other materials hereinbefore described, combinedwith a reducing agent and magnesium oxide or other metal oxides withphosphoric acid or monopotassium phosphate and acrylate to form theceramic phosphate formulations hereinbefore described. The reducingagents to be used in ferroceramicrete may be a variety of materialsincluding elemental metals, tin chloride, ferric sulfate or othertypical low costs moities.

An aqueous slurry of the ceramic has a compressive strength similar tothat of Portland cement, approximately 4000 psi. However, the slurryfrequently sets very rapidly and can be retarded in the rapidity withwhich it sets, as set forth in the previously incorporated '498 patent.In general, as previously stated, the ceramicrete and ferroceramicretedisclosed in the above-mentioned applications can be used in solidparticulate form at the construction site and either premixed with solidstyrofoam and acrylate prior to arrival at the construction site ormixed at the construction site. As previously disclosed, the phosphateceramic of the invention may be made from a source of phosphate and oneor more of an oxide, hydroxide or carbonate of one or more of Si, Fe,Mg, Al, Mn, Ca, Zr or mixtures thereof.

The inventors have discovered that by adding an acrylate such aspolyacrylic acid sodium salt, or any other suitable salt,polymethylmethacrylate or polyacryl amide or other suitable acrylatessuch as polyacrylnitrile or others in combination with polystyrene toform an aqueous slurry of the Ceramicrete® or Ferroceramicrete binderwith the acrylate and styrofoam, the resultant material when applied toa styrofoam base forms not merely a physical bond as previously occurredin the art, but a chemical bond which is firmly adhered to the styrofoambase thereby providing a inexpensive and easy mechanism by which to coatstyrofoam based forms on site. Ceramicrete® and Ferroceramicrete aretrademarks of Argonne National Laboratory but are used herein to denotethe phosphate ceramics made by the processes disclosed in theabove-incorporated patents and publication.

By way of note, the '809 patent teaches a surface coating material usedto reduce the leaching of soluble salts from ceramicrete waste forms.However, the resin there disclosed cannot be mixed with the Ceramicrete®aqueous slurry because the resins are not water based. Moreover, thematerials there disclosed are not suitable for use with polystyrene foambecause it collapses the foam structure. The materials used in the '809patent are styrene solvent and benzoyl peroxide, both of thesecomponents being toxic and not useful in the construction industry.

The present invention fulfills a significant requirement in theconstruction industry in warm climates in that the present inventionprovides polymers which with Ceramicrete® will bond chemically to apolystyrene foam surface. The invention consists of water solublematerials that can be applied in an aqueous Ceramicrete® slurry and donot adversely affect the setting properties of the Ceramicrete® slurry.Moreover, when set, the added polymers do not significantly alter themechanical and physical properties of the Ceramicrete® orFerroceramicrete material, and more particularly, the polymers do notintroduce porosity in the Ceramicrete® or Ferroceramicrete material anddo not render the set material water soluble.

As previously stated, there are a number of polymers which are watersoluble and compatible with the aqueous slurry of Ceramicrete® orFerroceramicrete particles. These water soluble polymers include theacrylates such as polyacrylic acid (AA) salt, preferably the sodiumsalt, polymethylmethacrylate (PMMA), polyacryl amide and others such aspolyacrylnitryl. The acrylate salts when dissolved in water producecarboxylate anions COO⁻ by releasing sodium ions into the solution. Thedissolution may be written as COONa . . . →COO⁻+Na⁻. The dissolution isillustrated in FIG. 1. In addition to dissolution of AA in aqueoussolution of Ceramicrete slurry, dissolution of MgO in the acidicCeramicrete slurry forms Mg(aq)⁺⁺. The two ions will react to produceCOOMg⁺ complexes. The complex may be of the type COO⁻—Mg—OOC, in whichcase, one Mg cation will satisfy two carboxylate ion. In anothermechanism, only one carboxylate ion may be bonded to Mg cation and thecation in turn bonds to one of the anions from the Ceramicrete matrix.The first possibility stabilizes AA partially (FIG. 3) and the secondpossibility will provide a bonding between Ceramicrete matrix and thepolymer (FIG. 2). These reactions may be written as follows:

-   Dissolution of MgO: MgO+2H⁺═Mg(aq)⁺⁺+H₂O-   Complete complexation of AA and Mg:    COO—+Mg: COO⁻+Mg(aq)⁺⁺+⁻OOC═COO—Mg—OOC-   Partial complexation of AA and Mg: :—COO—+Mg(aq)⁺⁺=—COO—Mg⁺

AA by itself, however, needs to be polymerized to form a stablecomponent in the matrix. To form a copolymer, styrene (C₆H₅CH═CH₂) isadded to the composition. Styrene will bond to AA as shown in FIG. 3.This reaction forms a stable polymer within the Ceramicrete® matrix.

The bonding between the Ceramicrete composite matrix and Styrofoam isfacilitated by the reaction of styrene and AA in the same manner asabove again as shown in FIG. 3. A similar complexation also occurs if anamide is used instead of styrene and also with use of PMMA, or othersuitable acrylate.

Table 1 lists various attempts to bind Ceramicrete® and styrofoam. Ineach case, Ceramicrete® slurry was made in a conventional way, with 7-9wt. % MgO, 18 et,. % KH₂PO₄, 50 wt. % sand and the rest Class F fly ash.To this as added 12 wt. % water. The slurry was mixed for 25 minutes.Each batch was approximately 500 Grams. AA and styrene beads were addedat different times as shown in Table 1. The slurry was then poured overa surface of dense styrofoam and was allowed to set. Typical thicknessof the Ceramicrete® layer was 0.5 cm. The following criteria were usedto test if the product was acceptable as a structural material to besprayed on styrofoam walls.

-   -   1. The slurry should warm up in 25 minutes    -   2. It should set into a hard ceramic within another hour,    -   3. The bond between Styrofoam and Ceramicrete composite should        be chemical.

The last criterion was tested by inserting a spatula between theCeramicrete® and styrofoam and lifting it up to open the interface. Ifthe whole cast of Ceramicrete® separated from the Styrofoam, then it wasconsidered to be only a physical bond. If on the other hand, theCeramicrete® cast or styrofoam broke at the tip of the spatula and therest of the material retained good adhesion, then it was considered tobe a good chemical bond.

As seen in Table 1, the bonding was chemical only when styrene or excessMgO were used along with AA. In the first case, it shows thatCeramicrete® itself with styrofoam sheet. In the second case, adding ofonly AA did not achieve the desired result. In fact, it adverselyaffected the setting of Ceramicrete®. In the third case, Ceramicrete®reacted with AA and excess MgO to provide a chemical bond. Although 10%excess MgO is reported in Table 1, excess MgO may be present in therange of from 1 to about 20% by weight, more preferably 11 to about 10%by weight, and most preferably about 10% by weight. In the last twocases, however, styrene reacted with AA and provided the necessarychemical bonding between styrofoam and Ceramicrete®, and also stabilizedAA within Ceramicrete®. TABLE 1 Various admixtures of Poly-ceramicreteand the results Ceramicrete and Mode of Heat generation at Nature ofPolymer composition Application 25 min and setting time BondingCeramicrete ® only Poured on Styrofoam Warmed up, One hour Physicalsetting Ceramicrete ® with Same as above, AA Less warming, Physical,Ceramicrete ® AA only added to slurry, Long time to set was set butslightly wet Ceramicrete ® with Same as above, AA More warming, ChemicalAA and 10% added to slurry short time to set additional magnesium oxideStyrene beads The solution was Warmed up, one Chemical dissolved in hotAA mixed with Ceramicrete ® hour setting solution powder and slurry wasformed, mixed for 25 min. and poured Mixture of styrene Mixed slurry for25 Warmed up, One Chemical and AA added to min. and poured on hoursetting Ceramicrete ® powder Styrofoam

As may be seen therefore, there has been disclosed a structural materialand a method of making same in which the aqueous slurry of particles ofa solid phosphate ceramic composite and a polyacrylic acid or acrylateor combinations or salts thereof are combined with either polystyrene orexcess MgO to form a reaction product which chemically bonds to apolystyrene base. More particularly, the solid phosphate ceramiccomposites may include the reaction product of a source of phosphatesuch as phosphoric acid or monopotassium phosphate and an acrylate.Further, the ceramic component may be one or more of a metal oxide orhydroxide. The structural material disclosed herein may include theoxide wherein the oxide or hydroxide is one or more of Si, Fe, Mg, Al,Mn, Ca, Zr or various mixtures or combinations thereof. As before statedin the incorporated patents, the solid phosphate ceramic generallyincludes alkali metal ions and more particularly and preferably alkalimetal potassium ions. Various polyacrylates may be used includingpolyacrylic acid or polymethymethacrylate or the sodium salt ofpolyacrylic acid. Additionally, polyacrylamide may also be employed.

In general, the acrylic acid or acrylate or combinations of saltsthereof may be present in the aqueous solution in the range of fromabout 3% by weight to about 8% by weight. More preferably, in the rangeof from about 4% by weight to about 6% by weight. More preferably, thepolyacrylic acid or polyacrylate or combinations of salts thereof ispresent in the aqueous slurry at a concentration of about 5% by weight.The polystyrene which may be used to form the chemical bond incombination with the other materials hereinbefore set forth may begenerally present in the aqueous solution in the range of from about 1%by weight to about 10% by weight.

The structural material disclosed in the above specification isparticularly useful, as hereinbefore stated, in combination withpolystyrene base materials in warm climate construction. As beforestated, the slurry of particles of solid phosphate ceramic componentalong with a suitable acrylate or salt thereof in combination witheither or both of styrene and excess magnesium oxide will provide thechemical bond required to obtain the benefits of the present invention.When excess MgO over and above the stoichiometric amount are needed inthe slurry is used, it may be present in a range of from about 1% toabout 20% by weight, more preferably in the range of from about 1% toabout 10% by weight and most preferably about 10% by weight. The methodof chemically bonding a structural material to a polystyrene base hasbeen disclosed in which an aqueous solution of particulate solidphosphate ceramic composite particles and either polystyrene particlesor an excess of MgO or both and a polyacrylate or a polyacrylic acid orsalt thereof has been used to form a aqueous reaction product which whenapplied to polystyrene base reacts to form a dried reaction productchemically bound to the polystyrene base, all as hereinbefore disclosed.

While particular embodiments of the present invention have been shownand described, it will be obvious to those skilled in the relevant artthat changes and modifications may be made without departing from theinvention in its broader aspects. Therefore, the aim in the appendedclaims is to cover all such changes and modifications as fall within thetrue spirit and scope of the invention. The matter set forth in theforegoing description and accompanying drawings is offered by way ofillustration only and not as a limitation. The actual scope of theinvention is intended to be defined in the following claims when viewedin their proper perspective based on the prior art.

1-12. (canceled)
 13. A structural material comprising a polystyrenebase, and the reaction product of the polystyrene base and an aqueousslurry of a solid phosphate ceramic comprising the product from thereaction of one or more of a metal oxide or a metal hydroxide with asource of phosphate to produce a phosphate ceramic and a poly (acrylicacid or acrylate) or combinations or salts thereof and polystyreneapplied to said polystyrene base and allowed to cure, whereby the driedaqueous slurry is chemically bonded to the polystyrene base.
 14. Thestructural material of claim 13, wherein the polystyrene base is apolystyrene foam.
 15. The structural material of claim 14, wherein thesolid phosphate ceramic composite includes the reaction product of asource of phosphate and one or more of a metal oxide or hydroxide orcarbonate.
 16. The structural material of claim 15, wherein the oxide orhydroxide or carbonate is one or more of Si, Fe, Mg, Al, Mn, Ca, Zr ormixtures thereof.
 17. The structural material of claim 16, wherein thesolid phosphate ceramic composite includes alkali metal ions therein.18. The structural material of claim 17, wherein said alkali metal ionsare potassium.
 19. The structural material of claim 17, wherein thepolyacrylate is polymethylmethacrylate.
 20. The structural material ofclaim 17, wherein the polyacrylic acid salt is a sodium salt.
 21. Thestructural material of claim 17, wherein the poly (acrylate) is apolyacryl amide.
 22. The structural material of claim 17, wherein thepoly(acrylic acid or acrylate) or combinations or salts thereof ispresent in the aqueous slurry in the range of from 3% by weight to about8% by weight.
 23. The structural material of claim 22, wherein thepoly(acrylic acid or acrylate) or combinations or salts thereof ispresent in the aqueous slurry in the range of from 4% by weight to about6% by weight.
 24. The structural material of claim 23, wherein thepoly(acrylic acid or acrylate) or combinations or salts thereof ispresent in the aqueous slurry in a concentration of about 5% by weight.25. The structural material of claim 24, wherein the polystyrene ispresent in the aqueous slurry in the range of from 1% by weight to about10% by weight.
 26. The structural material of claim 25 and furtherincluding excess MgO. 27-35. (canceled)